owner’s manual - tohatsu marineprinted in japan 100.2016.09 スミ tohastu blue bft 115a 150a...

Printed in Japan100.2016.09

Tohastu Blueスミ

BFT 115A150A

OWNER’S MANUAL

31ZX1T1100X31-ZX1-T110

BFT 115A150A TOHATSU CORPORATIONAddress : 5-4,AZUSAWA 3-CHOME ITABASHI-KU, TOKYO 174-0051Phone : +81-3-3966-3117FAX : +81-3-3966-2951

URL : www.tohatsu.co.jpFMAB

Keep this Owner’s Manual handy, so you can refer to it at any time. This Owner’s Manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects,

or other reproductive harm.

California Proposition 65This product contains or emits chemicals known to the state of California to cause

cancer, birth defects or other reproductive harm.

31ZX1T11.book 0 ページ２０１６年９月６日　火曜日　午後１１時１５分

1

INTRODUCTIONCongratulations on your selection of a TOHATSU outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market.

We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains information on how to do that; please read it carefully.

As you read this manual you will find information preceded by a symbol. That information is intended to help you avoid damage to your outboard motor, other property, or the environment.

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership.

When your outboard motor needs scheduled maintenance, keep in mind that your TOHATSU dealer is specially trained in servicing TOHATSU outboard motors. Your TOHATSU dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes,Tohatsu Corporation


2

INTRODUCTION

A FEW WORDS ABOUT SAFETY

Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining an outboard motor. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

• Safety Labels – on the outboard motor.

• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

• Safety Headings – such as IMPORTANT SAFETY INFORMATION.

• Safety Section – such as OUTBOARD MOTOR SAFETY.

• Instructions – how to use this outboard motor correctly and safely.

This entire book is filled with important safety information – please read it carefully.

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.


CONTENTS

3

OUTBOARD MOTOR SAFETY ................................... 7IMPORTANT SAFETY INFORMATION .............. 7SAFETY LABEL LOCATION ................................ 9

CONTROLS AND FEATURES ................................... 10CONTROL AND FEATURE IDENTIFICATION

CODES ................................................................ 10HOW TO DETERMINE WHICH DIRECTION

THE PROPELLER SHAFT ROTATES ............. 10COMPONENT AND CONTROL LOCATIONS ... 11CONTROLS ............................................................ 15Side-Mount Type

Ignition Switch .................................................... 15Emergency Stop Switch Clip and Emergency

Stop Switch ..................................................... 15Gearshift/Throttle Control Lever ........................ 16Fast Idle Lever ..................................................... 17

Panel-Mount TypeIgnition Switch .................................................... 18Emergency Stop Switch Clip and Emergency

Stop Switch ..................................................... 19Gearshift/Throttle Control Lever ........................ 20Fast Idle Button ................................................... 21

Top-Mount TypeIgnition Switch ....................................................22Emergency Stop Switch Clip and Emergency

Stop Switch ......................................................22Gearshift/Throttle Control Lever .........................23Fast Idle Button ...................................................25

Common ControlsPower Trim/Tilt Switch .......................................26Power Tilt Switch ................................................27Manual Relief Valve ............................................27Tilt Lock Lever ....................................................27TRL (Trolling) Control Switch.............................28Engine Cover Latch .............................................28Trim Tab ..............................................................29

INSTRUMENTS .....................................................29Trim Meter (optional equipment) ........................29Tachometer (optional equipment) .......................29NMEA Interface Coupler ....................................30Operating Hour Notification System ...................30


CONTENTS

4

INDICATORS ......................................................... 33Alternator (ACG) Indicator ................................. 33Malfunction Indicator .......................................... 33Oil Pressure Indicator .......................................... 34Overheat Indicator ............................................... 34Cooling System Indicator .................................... 35

OTHER FEATURES .............................................. 35Water Separator Buzzer ...................................... 35Rev Limiter ......................................................... 36Anodes ................................................................. 36Fuel Priming Bulb ............................................... 36

BEFORE OPERATION ................................................ 37ARE YOU READY TO GET UNDERWAY? ....... 37IS YOUR OUTBOARD MOTOR

READY TO GO? ................................................ 37

OPERATION .................................................................39SAFE OPERATING PRECAUTIONS ...................39BREAK-IN PROCEDURE .....................................39FUEL PRIMING .....................................................40INFREQUENT OR OCCASIONAL USE ..............40STARTING THE ENGINE .....................................41

Side-Mount Type .................................................41Panel-Mount Type ...............................................44Top-Mount Type ..................................................46

STOPPING THE ENGINE ......................................49Emergency Engine Stopping ...............................49Normal Engine Stopping .....................................50

GEARSHIFT AND THROTTLE OPERATION .................................51

STEERING ..............................................................52CRUISING ..............................................................53

Trolling Speed Control .........................................55TRIM TAB ..............................................................56SHALLOW WATER OPERATION .......................56MOORING, BEACHING, LAUNCHING ..............57MULTIPLE OUTBOARD MOTORS .....................58


CONTENTS

5

SERVICING YOUR OUTBOARD MOTOR ............... 59THE IMPORTANCE OF MAINTENANCE .......... 59MAINTENANCE SAFETY ................................... 60TOOL KIT and OWNER’S MANUAL .................. 61SPARE EMERGENCY STOP SWITCH CLIP ...... 61MAINTENANCE SCHEDULE .............................. 62TRIM TAB ADJUSTMENT ................................... 64MANUAL RELIEF VALVE .................................. 65ENGINE COVER REMOVAL AND

INSTALLATION ................................................ 65Engine Oil Level Check ...................................... 66Engine Oil Change .............................................. 67Oil Filter Change ................................................. 69Engine Oil Recommendations ............................. 70Lubrication Points ............................................... 71Spark Plug Service .............................................. 73

REFUELING ...........................................................77FUEL RECOMMENDATIONS ..............................77

Fuel Filter Inspection and Replacement ..............78Water Separator Inspection and Service ..............81Anode Replacement .............................................83Propeller Replacement .........................................83

CLEANING AND FLUSHING .....................................85Cleaning and Flushing .........................................85

STORAGE .....................................................................87Fuel ......................................................................87Engine Oil ............................................................89

HOISTING THE OUTBOARD MOTOR ...............90STORAGE PRECAUTIONS ..................................90REMOVAL FROM STORAGE ..............................91


CONTENTS

6

TRANSPORTING ......................................................... 92WITH OUTBOARD MOTOR

INSTALLED ON BOAT .................................... 92WITH OUTBOARD MOTOR

REMOVED FROM BOAT ................................. 92

TAKING CARE OF UNEXPECTED PROBLEMS ..... 93ELECTRIC STARTER WILL NOT OPERATE .... 93ENGINE WILL NOT START ................................ 94HARD STARTING OR STALLS AFTER

STARTING ......................................................... 96ENGINE OVERHEATS ......................................... 97FUSES ..................................................................... 98

Electric Starter Will Not Operate ........................ 98Battery Will Not Charge ..................................... 98Fuse Replacement ............................................... 98

OIL PRESSURE INDICATOR TURNS OFF AND ENGINE SPEED IS LIMITED ......................... 100

OVERHEAT INDICATOR COMES ON AND ENGINE SPEED IS LIMITED ......................... 101

WATER SEPARATOR BUZZER SOUNDS ....... 103SUBMERGED OUTBOARD MOTOR ................ 103

TECHNICAL INFORMATION ..................................105Serial Number Locations ...................................105Battery ...............................................................106Emission Control System Information ..............106Star Label ...........................................................109Specifications .....................................................111

CONSUMER INFORMATION ..................................113Emission Control System Warranty ..................113

INDEX .........................................................................118


7

OUTBOARD MOTOR SAFETYIMPORTANT SAFETY INFORMATION

TOHATSU BFT115A and BFT150A outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

Most injuries or property damage can be prevented if you follow all instructions in this manual and on the outboard motor. The most common hazards are discussed in this chapter, along with the best way to protect yourself and others.

Operator Responsibility

• It is the operator’s responsibility to provide the necessary safeguards to protect people and property. Know how to stop the engine quickly in case of emergency. Understand the use of all controls.

• Stop the engine immediately if anyone falls overboard, and do not run the engine while the boat is near anyone in the water.

• Always stop the engine if you must leave the controls for any reason.

• Attach the emergency stop switch lanyard securely to the operator.

• Always wear a PFD (Personal Flotation Device) while on the boat.

• Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

• Be sure that anyone who operates the outboard motor receives proper instruction.

• Be sure the outboard motor is properly mounted on the boat.

• Do not remove the engine cover while the engine is running.


8

OUTBOARD MOTOR SAFETY

Refuel With Care

• Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-ventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away.

• Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank.

• After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.

Carbon Monoxide Hazard

Exhaust contains poisonous carbon monoxide, a colorless, odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

If you run the engine in an area that is confined, or even partly enclosed, the air you breathe could contain a dangerous amount of exhaust gas.

Never run your outboard inside a garage or other enclosure.


9

OUTBOARD MOTOR SAFETY

SAFETY LABEL LOCATION

The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized TOHATSU dealer for a replacement.


10

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

Model BFT115A BFT150A

Type LA XA XCA LA XA XCA

Transom Height(Shaft Length)

20.0 in (508 mm) ● ●

25.0 in (635 mm) ● ● ● ●

Standard Rotating Propeller Shaft ● ● ● ●

Counterrotating Propeller Shaft ● ●

Power Trim/Tilt ● ● ● ● ● ●

DestinationA: AmericanRotating direction of propeller shaftC: Counterrotating propeller shaftNone: Standard rotating propeller shaftTransom HeightL: 20.0 in (508 mm), X: 25.0 in (635 mm)

X C ATYPE CODE (example)

HOW TO DETERMINE WHICH DIRECTION THE PROPELLER SHAFT ROTATES

The direction the propeller shaft rotates can be determined based on whether or not the shaft has a groove.With groove: CounterrotatingWithout groove: Standard rotating

WITHOUT GROOVE

WITH GROOVE

GROOVE


11


COMPONENT AND CONTROL LOCATIONS

ENGINE COVER LATCH

STERN BRACKET

MANUAL RELIEF VALVE

ANODE

[Example: BFT115A] PROPELLER(optional equipment)

EXHAUST PORT/WATER OUTLET PORT

ANTIVENTILATION PLATE

ANODE

COOLING SYSTEM INDICATOR

ENGINE COVER SPARK PLUG (under coil)

OIL LEVEL DIPSTICK

ENGINE OIL DRAIN BOLT (inside cover)

FLUSH PORT CONNECTOR

ANODE

TRIM TAB GEAR OIL DRAIN/FILL SCREW

COOLING WATER INTAKE PORT

GEAR OIL LEVEL CHECK SCREW

PRODUCT IDENTIFICATION NUMBER

TILT LOCK LEVER

POWER TILT SWITCH

NMEA INTERFACE COUPLER

OIL FILLER CAPJUNCTION BOX(FUSES)


12


GEARSHIFT/THROTTLECONTROL LEVER

Remote Controls (optional equipment)

Side-Mount Control Type

POWER TRIM/TILT SWITCH

BUZZER (inside)

CONTROL LEVER FRICTION ADJUSTER

EMERGENCY STOP SWITCH LANYARD

EMERGENCY STOPSWITCH CLIP

EMERGENCYSTOP SWITCH

IGNITION SWITCH KEY

FAST IDLE LEVER

IGNITION SWITCH

INDICATORS(Oil pressure, Overheat,Alternator, Malfunction)

NEUTRAL RELEASE LEVER

Panel-Mount Control TypeGEARSHIFT/THROTTLECONTROL LEVER

POWER TRIM/TILTSWITCH

NEUTRAL RELEASELEVER

FAST IDLE BUTTON

Control Panel(for Panel-Mount Type)

BUZZER

IGNITIONSWITCH


EMERGENCY STOPSWITCH LANYARD



TRL (Trolling) CONTROL SWITCH


13



Top-Mount Type(Single Outboard Motor Type)


FAST IDLE BUTTON

Control Panel(Top-Mount Single Type)

BUZZER

IGNITIONSWITCH





(Dual Outboard Motor Type)

GEARSHIFT/THROTTLECONTROL LEVERSPOWER TRIM/TILT

SWITCH (RIGHT)

POWER TRIM/TILTSWITCH (LEFT)

FAST IDLE BUTTON

(for Top-Mount Dual Type)


14


Instruments(optional equipment)Tachometer

Trim Meter

Trolling Control Switch Panel



15


CONTROLS

Side-Mount Type

Ignition Switch

The ignition switch controls the ignition system and the starter motor.

Turning the ignition switch key to the START position operates the starter motor. The key automatically returns to the ON position when released from the START position.

The engine will not start unless the gearshift/throttle control lever is in the N (neutral) position (p. 41) and the emergency stop switch clip is in the emergency stop switch.

Turning the ignition switch to the OFF position stops the engine.

Emergency Stop Switch Clip and Emergency Stop Switch

ON START

OFF

IGNITION SWITCH

EMERGENCY STOP SWITCH

EMERGENCY STOP SWITCH CLIP

EMERGENCYSTOP SWITCHLANYARD




16


The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device).

When used as described, the emergency stop switch clip and emergency stop switch lanyard system stops the engine if the operator falls away from the controls.

A spare switch clip (optional equipment) can be stored in the tool bag.

Gearshift/Throttle Control Lever

The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears.

SPARE SWITCH CLIP(optional equipment) NEUTRAL RELEASE

LEVER



17


Moving the control lever 32° from N (neutral) selects the gear, and further movement increases engine speed.

The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

A friction adjuster adjusts the operating resistance of the control lever. Refer to p. 52.

Less friction allows easier control lever movement. More friction helps to hold a steady throttle setting while cruising.

Fast Idle Lever

Use the fast idle lever to accelerate engine warm-up after starting the engine. Do not use the fast idle lever when starting the engine.

See page 43 for engine warm-up instructions.

FAST IDLE LEVER


MAXIMUM

MAXIMUM

THROTTLE OPENING

THROTTLE OPENING

MINIMUMMINIMUM

SHIFT SHIFT

F (FORWARD) R (REVERSE)32°32°N (NEUTRAL)


18


The fast idle lever allows you to increase the idle speed only when the control lever is in the N (neutral) position. Place the fast idle lever in its lowest position to cancel the fast idle and return the control lever to normal operation.

Panel-Mount Type

Ignition Switch





MAXIMUM FAST IDLE

FAST IDLE LEVER

LOWESTPOSITION

N (neutral)

IGNITION SWITCH

OFF

ONSTART


19











SPARE SWITCH CLIP(optional equipment)


20


Gearshift/Throttle Control Lever

The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears.


The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

A friction adjuster near the base of the control lever adjusts the operating resistance of the control lever. Refer to p. 52.



NEUTRALRELEASELEVER


MAXIMUM

MAXIMUM

THROTTLE OPENINGTHROTTLE OPENING

MINIMUMMINIMUM

SHIFT SHIFTF (FORWARD) R (REVERSE)35°35°

N (NEUTRAL)


21


Fast Idle Button

Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.


The fast idle button allows you to increase the idle speed without engaging the drive gears. Move the control lever forward or reverse after pushing in the fast idle button to increase the idle speed.

It is necessary to position the control lever in the N (neutral) position to push in the fast idle button.

Return the control lever to N (neutral) position to cancel the fast idle operation.

FAST IDLE BUTTON

CONTROLLEVER

N (neutral)F (forward)

R (reverse)

Push

FAST IDLE BUTTON

NEUTRALRELEASELEVER

Pull up


22


Top-Mount Type

Ignition Switch






START

IGNITION SWITCH

ON

OFF







23





Gearshift/Throttle Control Lever The gearshift/throttle control lever(s) controls engine speed and selects F (forward), N (neutral), or R (reverse) gears.

SPARE SWITCH CLIP(optional equipment)


SINGLE TYPE

DUAL TYPE

GEARSHIFT/THROTTLECONTROL LEVERS


24



A friction adjuster inside the control box adjusts the operating resistance of the control lever(s). Refer to p. 52.


N (NEUTRAL)

GEARSHIFT/THROTTLE CONTROL LEVER

35° 35°

R (REVERSE)F (FORWARD)SHIFT SHIFT

MINIMUM

MINIMUM

THROTTLE OPENING

THROTTLE OPENING

MAXIMUM

MAXIMUM


25


Fast Idle Button

Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.


The fast idle button allows you to increase the idle speed without engaging the drive gears. Move the control lever forward or reverse after pushing in the fast idle button to increase the idle speed.

It is necessary to position the control lever in the N (neutral) position to push in the fast idle button.

Return the control lever to N (neutral) position to cancel the fast idle operation.

FAST IDLE BUTTON

F (forward)

CONTROLLEVER

N (neutral)

R (reverse)

FAST IDLE BUTTON

Push


26


Common Controls

Power Trim/Tilt Switch


CONTROLLEVER

(Panel-Mount Type)


CONTROL LEVER (LEFT)(RIGHT)

CONTROLLEVERS

(Side-Mount Type) (Top-Mount Type)

SINGLE TYPE


DUAL TYPEPOWER TRIM/TILT SWITCH

CONTROL LEVER

The power trim/tilt switch is located on the control lever. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the outboard motor angle.

Trim the outboard motor to obtain the best performance and stability (p. 53).

Tilt the outboard motor for shallow water operation, beaching, launching, or mooring.

For dual mount outboard motors, tilt them up at the same time.


27


Power Tilt Switch

The power tilt switch is located on the engine pan. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

The power tilt switch will operate without turning the ignition switch ON.

This switch is used with the engine stopped to raise the outboard motor for mooring, trailering, or maintenance.

Manual Relief Valve

The outboard motor can be tilted manually after opening the manual relief valve. This allows the outboard motor to be tilted up or down when no battery is connected.

Check that nobody is under the outboard motor before opening the manual relief valve. If the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

Tilt Lock Lever

The tilt lock lever is used to support the outboard motor in the fully-raised position.

When the boat is to be moored for a long time, tilt the outboard motor up as far as it will go. Then move the tilt lock lever to the LOCK position, and gently lower the outboard motor until the lever contacts the stern bracket.

POWER TILT SWITCH

MANUAL RELIEF VALVE

POWER(To fix)

MANUAL(To release)

FREE

LOCK

TILT LOCK LEVER


28


TRL (Trolling) Control Switch(optional equipment; based on control box)

Remote Control Box (Side-Mount Type)

Trolling Control Switch Panel (optional equipment)

The TRL (Trolling) control switch is a rocker switch with UP and DN (down) positions to adjust the trolling speed up or down in 50 rpm increments within the range of 650 to 900 rpm.

If you press and hold the TRL control switch while cruising with the throttle closed, the mode changes to trolling mode (p. 55).

Engine Cover Latch

The engine cover latch fastens the engine cover to the outboard motor.



UNLOCK

ENGINE COVER LATCH


29


Trim Tab

The trim tab compensates for ‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted (p. 64), steering effort is equal in both directions.

INSTRUMENTS

Trim Meter(optional equipment)

The trim meter indicates the relative trim angle of the outboard motor.

Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat.

Tachometer(optional equipment)

The tachometer shows engine speed in revolutions per minute.

Refer to the tachometer when using the throttle and power trim/tilt controls to achieve the best performance from the boat.

TRIM TABBOLT

TRIM TAB


30


NMEA Interface Coupler

The NMEA2000® interface coupler can provide information regarding engine speed, fuel consumption, and various warnings to an existing NMEA2000 network via an optional interface cable. Contact your dealer for more information.

Operating Hour Notification System

This outboard motor engine counts the number of operating hours since the last periodic maintenance. When the next periodic maintenance is due, the engine notifies the NMEA2000 network, and a maintenance indication is displayed on an NMEA2000-compatible device.

After periodic maintenance is performed, reset the hour counter by:1. Stopping the engine.2. Setting the gearshift at F or R.3. Turning the ignition switch ON.

The buzzer will sound once.4. Pressing the emergency stop switch

5 times within 20 seconds.The buzzer will sound once when the hour counter is reset.

Periodic maintenance is required when either the operating hours or the time since last maintenance reaches the prescribed limit. Therefore, periodic maintenance may be required based on the number of months since the last maintenance before the alert based on engine operating hours displays (see MAINTENANCE SCHEDULE on page 62).Reset the hour counter whenever maintenance is performed, whether based on the time interval or the number of operating hours.

NMEA INTERFACE COUPLER


31


Steps 1 2 3 4

Outboard motor —

Ignition switch ON Start engine Gear at F or R

Display Switch ON — — —

Maintenance indication on

display

Not shown Shown Shown Not shown

Every 100 hours

100 hours after reset

80 hours after reset

20 hours

Start of operation

Notify Notify Notify

Maintenance indication




NMEA2000-compatible display:• Follow instructions for the display.• If the display allows selection of

notification to be preset, select “Notify” (or equivalent).

• Turn on the power supply to the display before turning on the ignition switch of the outboard motor.

• The indication may differ, depending on the type of display.


32


When "Periodic Maintenance" is indicated:1. Have the periodic maintenance

performed without delay after returning to port.

2. Reset the hour counter. If not reset, the maintenance indication will remain in the display, and the hour count until the next maintenance will be in error.

When the periodic maintenance is conducted before "Periodic Maintenance" is indicated, reset the hour counter.If not reset, the hour count until the next maintenance will be in error.


33


INDICATORS

The indicator lights come on and the buzzer sounds when you turn the ignition switch ON, allowing you to see that they are working. If an indicator does not light during this test, it cannot alert you if that system develops a problem. Have your TOHATSU dealer check for burned-out bulbs or other problems. Under normal conditions, the following occur when the ignition switch is turned ON:1. The ACG, Malfunction, Oil

Pressure, and Overheat indicators light.

2. The buzzer will beep twice.3. The Malfunction, Oil Pressure, and

Overheat indicators will go out after the second beep.

4. The ACG indicator will go out after the engine starts.

5. The Oil Pressure indicator will light again after the engine starts and will stay lit to indicate the oil pressure is normal.

Alternator (ACG) Indicator

The ACG indicator turns on and the buzzer sounds in one-second intervals when the charging system is faulty.

Malfunction Indicator

When the engine control system detects an engine control system malfunction, the malfunction indicator turns on and the buzzer sounds at one-second intervals.

ACG INDICATOR(side-mount type)

(RED)

BUZZER

(panel-mount/top-mount types)

ACG INDICATOR

(RED)

BUZZER

MALFUNCTIONINDICATOR

(side-mount type)

(RED)

(panel-mount/top-mount types)MALFUNCTIONINDICATOR

(RED)

BUZZER

BUZZER


34


Oil Pressure Indicator When the oil pressure indicator is lit, oil pressure is OK.

If oil pressure becomes low, the indicator will turn off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, on p. 100.

All models are equipped with a buzzer that sounds continuously when the oil pressure indicator turns off.

Low oil pressure indicates that the engine oil level is low or that there is a problem with the engine lubrication system.

Overheat IndicatorOIL PRESSUREINDICATOR

(side-mount type)

(GREEN)

(panel-mount/top-mount types)

OIL PRESSUREINDICATOR

(GREEN)

BUZZER

BUZZER

OVERHEATINDICATOR

(side-mount type)

(RED)

(panel-mount/top-mount types)OVERHEATINDICATOR

(RED)

BUZZER

BUZZER


35


When the alert triggers, the overheat indicator comes on and the buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine shuts off. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, on p. 101.

All models are equipped with a buzzer that sounds continuously when the red overheat indicator light comes on.

Engine overheating may be the result of clogged water intakes.

Cooling System Indicator

Water should flow from the cooling system indicator while the engine is running. This shows that water is circulating through the cooling system.

If water stops flowing while the engine is running, it indicates a cooling system problem, such as clogged water intakes, which will cause engine overheating.

The cooling system indicator discharge port can also become plugged.

OTHER FEATURES

Water Separator Buzzer

The water separator buzzer sounds a rapid, repeating signal when water has accumulated in the water separator.

COOLING SYSTEM INDICATOR

WATER SEPARATOR


36


Rev Limiter

The engine is equipped with a rev limiter to prevent the possibility of mechanical damage from excessive engine speed.

The rev limiter may be activated during operation, limiting engine speed, if the outboard motor is trimmed or tilted up excessively, or when propeller ventilation occurs during a sharp turn.

If the rev limiter is activated, check the trim angle of the outboard motor.

Check to see if the correct propeller is installed.

Anodes

The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion.

There are two anodes on the gear case, one on the stern bracket and two small anodes in the water passages of the engine block.

Fuel Priming Bulb

A priming bulb is built into the fuel hose that connects the fuel tank to the outboard motor.

Before starting the engine, hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine (p. 40).

ANODE(stern bracket)

ANODE(each side)

OUTLET END(outboard motor side)

INLET END (tank side)

UP

PRIMING BULB


37

BEFORE OPERATIONARE YOU READY TO GET UNDERWAY?

Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury.

Knowledge

Read and understand this manual. Know what the controls do and how to operate them.

Familiarize yourself with the outboard motor and its operation before you get underway. Know what to do in case of an emergency.

Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

Safety

Always wear a PFD (Personal Flotation Device) while on the boat.

Attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD.

IS YOUR OUTBOARD MOTOR READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the outboard motor to check its condition. Be sure to take care of any problem you find, or have your authorized TOHATSU dealer correct it, before you operate the outboard motor.

Before beginning your pre-operation checks, be sure the ignition switch is in the OFF position.

Improperly maintaining this outboard motor or failing to correct a problem before operation can cause a malfunction in which you could be seriously hurt or killed.

Always perform a pre-operation inspection before each operation, and correct any problem.


38

BEFORE OPERATION

Safety Inspection

• Before each use, look around and underneath the engine for signs of oil or gasoline leaks.

• Check that the fuel hose is undamaged and properly connected.

• Wipe up any spills before starting the engine.

• Check the stern bracket to be sure the outboard motor is securely installed.

• Check that all controls are operating properly.

• Replace any damaged parts.

• Check that all fasteners are in place and securely tightened.

• Check the emergency stop switch for proper operation. Start the engine (p. 41, 44 or 46). Make sure

the engine stops by pulling the emergency stop switch clip from the emergency stop switch.

Maintenance Inspection

• Check the engine oil level (p. 66). Running the engine with a low oil level can cause engine damage.Overfilling the engine can cause the engine to smoke or have oil leaks which can cause engine damage.

• Check to be sure the propeller is undamaged and the castle nut is secured with the cotter pin (p. 84).

• Check that the anodes are securely attached to the stern bracket and the gear case (p. 83) and are not excessively worn. The anodes help protect the outboard motor from corrosion.

• Make sure the tool kit is onboard (p. 61). Replace any missing items.

• Check the fuel level in the fuel tank (p. 77).

• Check that the battery fluid is between the upper and lower levels, and the battery leads are connected securely.

• Check the water separator for water contamination (p. 81).


39

OPERATIONSAFE OPERATING PRECAUTIONS

To safely realize the full potential of this outboard motor, you need a complete understanding of its operation and a certain amount of practice with its controls.

Before operating the outboard motor for the first time, please review the IMPORTANT SAFETY INFORMATION on page 7 and the chapter titled BEFORE OPERATION.

For your safety, do not start or run the engine in a confined or partly enclosed area. Your engine’s exhaust contains poisonous carbon monoxide, a colorless, odorless gas that can collect rapidly. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

BREAK-IN PROCEDURE

Break-in period: 10 hours

Proper break-in operation allows the moving parts to wear in smoothly for best performance and long service life. Avoid continuous operation at a steady speed.

First 15 minutes:Run the engine at trolling speed. Use the minimum throttle opening necessary to operate the boat at a safe trolling speed.

Next 45 minutes:Run the engine up to a maximum of 2,000 to 3,000 rpm, which is about 10% to 30% of maximum throttle opening. Operating at maximum 2,000 ~ 3,000 rpm should be limited to 50% of the 45 minutes.

Next 60 minutes:Run the engine up to a maximum of 4,000 to 5,000 rpm, which is about 50% to 80% of maximum throttle opening. Operating at maximum 4,000 ~ 5,000 rpm should be limited to 50% of the 60 minutes.

30-second full-throttle bursts are OK, but do not operate the engine continuously at full throttle.

For boats that plane easily, bring the boat up on plane, and then reduce the throttle opening to the recommended rpm range.

Next 8 hours:Do not run the engine at full throttle for more than 5 minutes at a time.


40

OPERATION

FUEL PRIMING

Hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine.

Check to be sure there are no fuel leaks before starting the engine.

Do not touch the priming bulb with the engine running or when tilting up the outboard motor. The vapor separator could overflow.

INFREQUENT OR OCCASIONAL USE

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the STORAGE chapter (p. 87) for additional information regarding fuel deterioration.

OUTLET END(outboard motor side)

INLET END(tank side)

UP

PRIMING BULB

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.• Wipe up spills immediately.


41

OPERATION

STARTING THE ENGINE

ControlSide-Mount Type ...................... p. 41Panel-Mount Type .................... p. 44Top-Mount Type ....................... p. 46

Side-Mount Type

1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or

to the operator’s PFD (Personal Flotation Device).

The engine will not start or run, unless the emergency stop switch clip is in the emergency stop switch.

The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.

Always attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine.

Before leaving the dock, check the operation of the emergency stop switch.

2. Set the control lever in the N (neutral) position.

The engine will not start if the F (forward) or R (reverse) gears are engaged.




CONTROLLEVER

N (neutral)


42

OPERATION

3. Leave the fast idle lever in the OFF (fully lowered) position.

The fast idle lever cannot be raised unless the control lever is in the N (neutral) position.

The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered.

4. Turn the ignition switch key to the ON position; the buzzer will sound twice.

5. Turn the ignition switch key to the START position and hold it there until the engine starts.When the engine starts, release the key, allowing it to return to the ON position.

If the engine fails to start within 5 seconds, release the key and wait at least 10 seconds before operating the starter again.

• Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

• Turning the ignition switch key to the START position while the engine is running can damage the starter motor and flywheel.

FAST IDLE LEVER

LOWESTPOSITION

START

IGNITION SWITCH KEY

ONOFF


43

OPERATION

6. Before getting underway, allow the engine to warm-up sufficiently to ensure good performance.

Above 41°F (5°C), warm-up the engine for at least 3 minutes.

Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.

• If the engine is not properly warmed up before raising the engine speed, the buzzer and overheat indicator may activate and the engine speed will be automatically reduced.

• The cooling system may freeze in areas where the temperature reaches 32°F (0°C) or below. Cruising at high speed without warming the engine up may cause engine damage.

During the warm-up period, check the oil pressure indicator (p. 34), overheat indicator (p. 34), and cooling system indicator (p. 35).

If the indicators show any abnormal condition, immediately stop the engine and determine the cause of the problem. Refer to TAKING CARE OF UNEXPECTED PROBLEMS on p. 100 – 103.

7. If the fast idle lever was used to warm-up the engine, gradually lower the lever as the engine warms up.

When the fast idle lever is fully lowered, the control lever can be moved away from the N (neutral) position.

FAST IDLERANGE

FAST IDLE LEVER

MAXIMUM FAST IDLE


44

OPERATION

Panel-Mount Type

1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD (Personal Flotation Device).







EMERGENCY STOPSWITCH



CONTROLLEVER

N (neutral)


45

OPERATION





• Turning the ignition switch key to the START position while the engine is running can damage the starter motor and flywheel. 5. Before getting underway, allow the

engine to warm-up sufficiently to ensure good performance.


Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm. Push the fast idle button, and then move the control lever forward or reverse to open the throttle and achieve approximately 2,000 rpm.

IGNITIONSWITCH KEY

STARTON

OFF

CONTROLLEVER

N (neutral)

FAST IDLE BUTTON


46

OPERATION





6. If the fast idle control was used to warm-up the engine, gradually return the control lever to the N (neutral) position as the engine warms up.

Top-Mount Type

1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD (Personal Flotation Device).





47

OPERATION









CONTROLLEVER

N (neutral)

IGNITIONSWITCH KEY

STARTON

OFF


48

OPERATION



• Turning the ignition switch key to the START position while the engine is running can damage the starter motor and flywheel. 5. Before getting underway, allow the

engine to warm-up sufficiently to ensure good performance.


Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm. Push the fast idle button, and then move the control lever forward or reverse to open the throttle and achieve approximately 2,000 rpm.



CONTROLLEVER

N (neutral)

FAST IDLE BUTTON


49

OPERATION



6. If the fast idle control was used to warm-up the engine, gradually return the control lever to the N (neutral) position as the engine warms up.

STOPPING THE ENGINE

Emergency Engine Stopping

To stop the engine in an emergency, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard.

We suggest that you stop the engine this way occasionally to verify that the emergency stop switch is operating properly.


Turn the ignition switch key to the OFF position after verifying the emergency stop switch operation.


Side-Mount Type



PULL

Panel-Mount/Top-Mount TypesEMERGENCYSTOP SWITCH

CONTROL PANELEMERGENCYSTOP SWITCHLANYARD

PULL

EMERGENCY STOP SWITCH CLIP


50

OPERATION

Normal Engine Stopping

1. Move the control lever(s) to the N (neutral) position.

After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine.

Side-Mount Type

2. Turn the ignition switch key to the OFF position to stop the engine. In the event that the engine does not stop when the ignition switch key is turned to OFF, press the emergency stop switch until the engine stops.

3. When the boat is not in use, remove and store the ignition switch key and the emergency stop switch clip and lanyard.

CONTROLLEVER

Side-Mount Type

Panel-Mount Type

N (neutral)

N (neutral)

CONTROLLEVER

CONTROLLEVER

Top-Mount TypeN (neutral)

IGNITION SWITCH KEY

OFF

IGNITIONSWITCH KEY

Panel-Mount/Top-Mount Types

OFF


51

OPERATION

GEARSHIFT AND THROTTLE OPERATION

To shift gears, move the control lever to select the F (forward), N (neutral), or R (reverse) gear.

The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed (side-mount/panel-mount types).

Moving the control lever beyond the gear selection range increases engine speed.NEUTRALRELEASE

LEVER

Side-Mount TypeCONTROL LEVER

N (neutral)

F (forward)

R (reverse)

NEUTRALRELEASELEVER

Panel-Mount Type

CONTROL LEVER


CONTROLLEVER


R (reverse)

Top-Mount Type

R (reverse)


52

OPERATION

Adjust the control lever friction adjuster so the control lever will hold a constant throttle setting while cruising.

STEERING

Steer the boat in the same manner as an automobile.

CONTROL LEVERFRICTION ADJUSTER

Side-Mount Type

TO INCREASEFRICTION


TO INCREASEFRICTION

TO DECREASEFRICTION

Panel-Mount Type

TO DECREASEFRICTION


Top-Mount Type

TO INCREASEFRICTION

TO DECREASEFRICTION


53

OPERATION

CRUISING

Engine Speed

For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 52) to help you hold a steady speed.

For rough water conditions or large waves, slow down to prevent the propeller from rising out of the water.

The engine is equipped with a rev limiter to prevent the possibility of mechanical damage from excessive engine speed.

If, for example, the outboard motor is tilted excessively or propeller ventilation occurs during a sharp turn, the engine may overrev, activating the rev limiter.If engine speed becomes unstable at high speed due to activation of the rev limiter, reduce speed and check the trim angle of the outboard motor.

Trim

Use the power trim/tilt switch to trim the outboard motor for the best performance and stability.

You can use the power trim/tilt switch at any time, whether the boat is underway or stopped.

Press the UP or DN (down) side of the switch to adjust the angle of the outboard motor.

Refer to the trim meter (p. 29) for an indication of whether the outboard motor is trimmed high or low.

It is necessary to trim the angle of the outboard motor to compensate for changes in boat load, weight distribution, water conditions, or propeller selection.

Under normal conditions, the boat will perform best when the antiventilation plate is level with the water surface.

When cruising into a high wind, trim the outboard motor down slightly to level the boat and improve stability. With a tail wind, trim the outboard motor up slightly.

Excessive trim/tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.


54

OPERATION

Side-Mount Type



Panel-Mount Type

Top-Mount Type



(single type)

(dual type)

(LEFT) (RIGHT)

OUTBOARDMOTOR TRIMMEDTOO LOW

OUTBOARD MOTOR TRIMMEDCORRECTLY

BOW TOO LOW DUE TO1. LOAD IN THE FRONT2. OUTBOARD MOTOR TRIMMED

TOO LOW

BOW TOO HIGH DUE TO1. LOAD IN THE REAR2. OUTBOARD MOTOR TRIMMED

TOO HIGH

OUTBOARDMOTOR TRIMMEDTOO HIGH


55

OPERATION

Trolling Speed Control

Remote Control Box (Side-Mount Type)

Trolling Control Switch Panel (optional equipment)

DN: Reduce engine speedUP: Increase engine speed

The engine must be fully warmed up before you can activate the Trolling Speed Control.Place the outboard motor in-gear with the throttle control in the fully closed (idle) position. Press and hold the UP or DN side of the TRL control switch to activate the Trolling Speed Control. The buzzer will make one long sound indicating activation.

The initial trolling speed is set at 650 rpm.The engine speed can be adjusted in 50 rpm increments by pressing the UP or DN side of the TRL control switch. A short sound of the buzzer occurs each time the engine speed is adjusted.In Trolling Speed Control mode, the engine speed can be adjusted between 650 and 900 rpm.Continuing to press the switch when at either of these limits will result in two short sounds from the buzzer.The throttle control will operate when in the Trolling Speed Control mode, but once the speed reaches 3,000 rpm, the Trolling Speed Control is deactivated. If 3,000 rpm is not reached and the throttle is closed, the engine speed will decrease to the Trolling Speed Control setting.




56

OPERATION

TRIM TAB

If steering effort is not equal in both directions, adjust the trim tab to compensate for ‘‘torque steer,’’ which is the reaction of the outboard motor to propeller rotation.

Adjust the trim tab with the engine stopped. Loosen the bolt above the trim tab, turn the trim tab, and then tighten the bolt securely.

When the trim tab is correctly adjusted, steering effort will be equal in both directions.

Refer to TRIM TAB ADJUSTMENT on p. 64.

SHALLOW WATER OPERATION

When operating in shallow water, use the power trim/tilt switch (p. 54) to tilt the outboard motor so that the propeller and gear case won’t hit the bottom.

Proceed at low speed, and monitor water flow from the cooling system indicator (p. 35) to be sure the outboard motor is not tilted so high that the water intakes are out of the water.TRIM TAB

TRIM TABBOLT

TRIM ANGLE(when transom angle is 12°)

12°

0°

– 4°0°(VERTICAL LINE)

16°

72°

TILT ANGLE


57

OPERATION

MOORING, BEACHING, LAUNCHING

Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine.

Stop the engine and disconnect the fuel hose from the outboard motor before tilting the outboard motor.

To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch on the engine pan to tilt the outboard motor up as far as it will go. Move the tilt lock lever to the LOCK position, and then gently lower the outboard motor until the lever contacts the stern bracket. Use the power tilt switch to fully shorten the trim rods.

To lower the outboard motor, tilt up using the power tilt switch, then move the tilt lock lever to the FREE position, and then lower the outboard motor to the desired position.

Do not attempt to use the power tilt switch to tilt the outboard motor down while the tilt lock lever is in the LOCK position. Damage to the power tilt system may occur.

TRIM RODS POWER TILT SWITCH

TILT LOCK LEVER(Lock position)

FREE

LOCK

STERN BRACKET


58

OPERATION

The outboard motor can also be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down when no battery is connected.

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the engine.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.


MULTIPLE OUTBOARD MOTORS

On boats equipped with more than one outboard motor, all motors normally operate at the same time.

If one or more motor(s) is stopped while the other(s) is running, put the stopped motor in ‘‘N’’ (neutral) and tilt it up so its propeller is above the water’s surface.

If the propeller of the stopped motor is left in the water, it may turn as the boat moves through the water, causing a reverse flow of water from the exhaust side. This reverse flow will happen if the stopped engine’s propeller is in the water, its gearshift is in ‘‘R’’ (reverse), and the boat is moving forward. Reverse flow can cause an engine malfunction.

MANUAL(To release)

MANUAL RELIEF VALVE

POWER(To fix)


59

SERVICING YOUR OUTBOARD MOTORTHE IMPORTANCE OF MAINTENANCE

Proper maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution.

To help you properly care for your outboard motor, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a TOHATSU technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your outboard motor under unusual conditions, consult an authorized TOHATSU dealer for recommendations applicable to your individual needs and use.

Remember that your authorized TOHATSU dealer knows your outboard motor best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, TOHATSU Genuine parts or their equivalents for repair and replacement.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual, using parts that are ‘‘certified’’ to EPA standards.

Improperly maintaining this outboard motor or failure to correct a problem before operation can cause a malfunction in which you could be seriously hurt or killed.

Always follow the inspection and maintenance recommendations and schedules in this Owner’s Manual.


60

SERVICING YOUR OUTBOARD MOTOR

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Safety Precautions

• Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

─ Carbon monoxide poisoning from engine exhaust.Do not start or run the engine in a confined or partly enclosed area.

─ Burns from hot parts.Let the engine and exhaust system cool before touching.

─ Injury from moving parts.Do not run the engine unless instructed to do so.

• Read the instructions before you begin, and make sure you have the tools and skills required.

• To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.

• Wear gloves when handling the propeller to protect your hands from sharp edges.

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in the Owner’s Manual.


61


TOOL KIT and OWNER’S MANUAL(Tool kit does not come with Counter Rotation Types)

The tool kit can be used for simple maintenance procedures and emergency repairs. Keep these items on the boat so that they will always be available if you need them.

If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually.

PHILLIPS/FLATSCREWDRIVER

GRIP

OWNER’S MANUAL 19 mm EYE WRENCH

SPARK PLUG WRENCH

6 mm HEX. WRENCH

TOOL BAG

SPARE EMERGENCY STOP SWITCH CLIP

Always carry a spare emergency stop switch clip onboard. The spare clip may either be stored in the tool bag or in an easily accessible location on the boat.


62


MAINTENANCE SCHEDULEFollow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly.

(1) Lubricate more frequently when used in salt water.(2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the

TOHATSU Service Manual for service procedures. (3) For professional commercial use, log hours of operation to determine proper maintenance intervals.(6) Replace the anodes when they have been reduced to about one third their original size, or if they are crumbling.

REGULAR SERVICE PERIOD (3)Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

Each use After use

Firstmonth

or20 hrs.

Every6 months

or100 hrs.

Everyyearor

200 hrs.

Every2 years

or400 hrs.

Refer topage

Engine oil Check level o 66Change o o

Engine oil filter Replace o (2) 69Gear case oil Change o (2) o (2) –ACG belt Check-adjust o (2) –Throttle linkage Check-adjust o (2) o (2) –Idle speed Check-adjust o (2) o (2) –Valve clearance Check-adjust o (2) –Spark plug(Standard plug)

Check-adjust/Replace o 73 – 75

Propeller and cotter pin Check o 84Anode metal Check Outside engine o 83Anode metal Check Inside engine o (2) (6) –Lubrication Grease o (1) o (1) 71 – 72Water separator Check o 81 – 82Fuel filter(Low pressure side)

Check o 78 – 80Replace o


63


(2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the TOHATSU Service Manual for service procedures.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.(4) When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.(5) Upon starting, check for unusual engine sounds and cooling water flowing freely from the check hole.(7) Check the fuel line for leaks, cracks or damage. If it is leaking, cracked or damaged, take it to your servicing dealer for replacement before

using your outboard.(8) Replace the fuel line if there are signs of leaks, cracks or damage.

REGULAR SERVICE PERIOD (3)Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

Each use After use

Firstmonth

or20 hrs.

Every6 months

or100 hrs.

Everyyearor

200 hrs.

Every2 years

or400 hrs.

Refer topage

Fuel filter(High pressure side)

Replace o (2) –

Thermostat Check o (2) –Fuel line Check o (7) 38

Replace Every 2 years (If necessary) (2) (8) –Battery and cable connection Check level-tightness o 38Bolts and nuts Check-tightness o (2) o (2) –Crankcase breather tube Check o (2) –Cooling water passages Clean o (4) –Water pump Check o (2) –Emergency stop switch Check o 38Engine oil leak Check o –Each operation part Check o –Engine condition (5) Check o –Power Trim/Tilt Check o (2) –Spark plug(Optional iridium plug)

Check o 76Replace o 76

Shift Cable Check-adjust o (2) –


64


TRIM TAB ADJUSTMENT

The trim tab compensates for ‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted, steering effort is equal in either direction.

If steering effort is unequal, loosen the trim tab bolt and adjust the angle of the trim tab. Retighten the trim tab bolt securely.

If less effort is required to make left turns, move the back of the trim tab left.

If less effort is required to make right turns, move the back of the trim tab right.

Adjust the trim tab in small increments, and retest steering effort with the boat evenly loaded and running at cruising speed.

LEFT

LEFT

TRIM TAB

TRIM TAB BOLT

RIGHT

RIGHT

TRIM TAB

TRIM TAB BOLT


65


MANUAL RELIEF VALVE

The outboard motor can be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down when no battery is connected.

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the outboard motor.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.


ENGINE COVER REMOVAL AND INSTALLATION The engine cover latch fastens the

engine cover to the outboard motor.

To remove the engine cover, pull the engine cover latch to the unlocked position, then lift the engine cover straight up from the outboard motor.

To install the engine cover, place the cover on the outboard motor, and push down evenly.

The cover should be tight at the mid-case point. If the cover is loose or difficult to secure, an adjustment may be necessary. Please see the service manual or your TOHATSU dealer for adjustment.

MANUAL RELIEF VALVE

POWER(To fix)

MANUAL(To release)

ENGINE COVER

UNLOCK

ENGINE COVER LATCH


66


Engine Oil Level Check

Check the engine oil level with the engine stopped and the outboard motor in the vertical position.

1. Unlock and remove the engine cover (p. 65).

2. Remove the dipstick and wipe it clean.

3. Insert the dipstick all the way in, then remove it and check the oil level shown on the dipstick.

4. If the oil level is low, remove the oil filler cap, and add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended on p. 70.

• Running the engine with a low oil level can cause engine damage.

• Do not overfill. Overfilling the engine will cause it to smoke or have oil leaks.

5. Install the oil filler cap and tighten it securely. Do not overtighten.

6. Install and lock the engine cover.

UPPERLIMIT

OIL LEVEL DIPSTICK

LOWERLIMIT

OIL FILLER CAP


67


When you check the oil level with the dipstick, you might notice the engine oil appears milky or the oil level has increased. If you notice either condition, change the engine oil. See the following table for an explanation of these conditions.

Operating Method Result Effect

Running the engine below 3,000 rpm for more than 30% of the time so the engine does not warm up.

• Water condenses in the engine and mixes with the oil, resulting in a milky appearance.

• Unburned fuel mixes with the oil, increasing the volume of oil.

The engine oil deteriorates, becomes less efficient as a lubricant, and causes an engine malfunction.

Frequent starting and stopping without allowing the engine to warm up.

Engine Oil Change

An engine oil evacuation device may be used to remove the engine oil.

Drain the used oil while the engine is warm. Warm oil drains quickly and completely.

1. Unlock and remove the engine cover (p. 65).

2. Push the drain bolt cover lever and remove the cover while pulling the cover backward at an angle.

DRAIN BOLT COVER

LEVER


68


3. Set the drain bolt cover under the guide.

4. Place a suitable container below the oil drain guide to catch the used oil, and then remove the oil filler cap, drain bolt, and sealing washer.

5. Allow the used oil to drain completely. Use a new sealing washer, and then reinstall the engine oil drain bolt and washer. Tighten the drain bolt securely.

DRAIN BOLT TIGHTENING TORQUE:17 lbf·ft (23 N·m, 2.3 kgf·m)

Improper disposal of engine oil can be harmful to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to a recycling center. Do not throw it in the trash, pour it on the ground or down a drain.

DRAIN BOLT COVER

GUIDE

GUIDE

DRAIN BOLT COVER

SEALING WASHER

GUIDEDRAINBOLT

DRAINBOLTCOVER

DRAIN BOLT COVER

UNDER COVER PUSH LEVER

PROJECTIONLOCKING LUG


69


6. Install the oil drain bolt cover. Push the lever of the oil drain bolt cover in the direction pointed by the arrow mark of ‘‘LOCK’’, and install the oil drain bolt cover so that the locking lug securely sets on the projection of the under cover.

7. With the outboard motor in a vertical position, fill to the upper limit mark on the dipstick (p. 66) with the recommended oil. Engine oil refill capacity: Without oil filter change:6.9 US qt (6.5 L)With oil filter change:7.1 US qt (6.7 L)

8. Install the oil filler cap and tighten it securely.

9. Install and lock the engine cover.

Oil Filter Change

1. Drain the engine oil, and then reinstall the drain bolt and sealing washer. Reinstall the drain bolt cover (see Engine Oil Change on p. 67).

2. Tilt the outboard motor, and place a suitable container below the oil drain guide to catch the used oil.

3. Use a suitable tool to remove the oil filter, and thoroughly drain the filter into the used oil container.

FILTER WRENCH, 65 mmOIL FILTER

OIL DRAIN GUIDE

RUBBER SEAL


70


4. Clean the oil filter mounting base, and coat the rubber seal of the new oil filter with clean engine oil.

Use only a TOHATSU Genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong filter, or a non-TOHATSU filter which is not of equivalent quality, may cause engine damage.

5. Screw on the new filter by hand until it contacts the engine, then use a suitable tool to tighten the filter an additional 3/4 turn.

OIL FILTER TIGHTENING TORQUE:9 lbf·ft (12 N·m, 1.2 kgf·m)

6. Return the outboard motor to the vertical position, and fill the crankcase with the specified amount of the recommended oil.

Do not overfill. Overfilling the engine will cause it to smoke or have oil leaks.

7. Start the engine and check for leaks (be sure the water level is at least 2 inches (5 cm) above the antiventilation plate).

If you are changing the oil filter while the outboard motor is out of the water, use commercially available ear muffs and water hose to supply water.

Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine.

8. Stop the engine, and check the oil level as described on page 66. If necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

Engine Oil Recommendations

Oil is a major factor affecting performance and service life. Use 4-stroke detergent oil.

Use 4-stroke high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for API Service category SG, SH or SJ. Motor oils classified SG, SH or SJ will show this designation on the container.

SAE 10W-30 is recommended for general use.

AMBIENT TEMPERATURE


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Apply corrosion inhibitor to all areas under the engine cover and any exposed metal surfaces except the belts.

PROPELLER SHAFT

Lubrication PointsApply TOHATSU Marine grease to the parts shown below:

Apply anticorrosion oil to pivot surfaces where grease cannot penetrate.

THROTTLE LINK/PIVOT/PLATE

ENGINE COVER BRACKET

PTT THRUST RECEIVER

SWIVEL CASE

TILT SHAFT

TILT BRACKETTHROTTLE ROD/LINK

[Example: BFT115A]


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COVER LOCK BOLTSENGINE COVER LOCKLEVER/OPEN SHAFT

ENGINE COVERCABLE (FRONT)

THROTTLE ARM/SHIFT ARM/PIVOTPLATE/NEU

owner’s manual - tohatsu marineprinted in japan 100.2016.09 スミ tohastu blue bft 115a 150a...

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